Tobacco-free pouched product containing flavor beads providing immediate and long lasting flavor release

ABSTRACT

A tobacco-free oral pouch product providing immediate and long lasting flavor release comprises a pouch wrapper and tobacco-free flavor beads contained within the pouch wrapper. The flavor beads comprise at least one of microcrystalline cellulose, pectin and sodium alginate, at least one polymer having a higher solubility in saliva than microcrystalline cellulose, pectin and/or sodium alginate, and at least one flavorant. The pectin and sodium alginate are cross-linked. The tobacco-free flavor beads provide immediate release of the flavorant upon placement of a pouch product in a user&#39;s mouth and long lasting release of the flavorant for about 15 minutes to about 80 minutes. The oral pouch product contains only tobacco-free flavor beads.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. application Ser.No. 12/577,034 entitled TOBACCO-FREE POUCHED PRODUCT CONTAINING FLAVORBEADS PROVIDING IMMEDIATE AND LONG LASTING FLAVOR RELEASE, filed on Oct.9, 2009, the entire content of which is hereby incorporated byreference.

SUMMARY

Provided is a tobacco-free oral pouch product containing flavor beadsproviding immediate and long lasting flavor release. The tobacco-freeoral pouch product comprises a pouch wrapper and tobacco-free flavorbeads contained within the pouch wrapper. The flavor beads comprise oneof microcrystalline cellulose, pectin and sodium alginate, at least onepolymer having a higher solubility in saliva than one ofmicrocrystalline cellulose, pectin and sodium alginate, and at least oneflavorant. The pectin and said sodium alginate are cross-linked. Thetobacco-free flavor beads provide immediate release of the flavorantupon placement in a user's mouth and long lasting release of theflavorant for about 15 minutes to about 80 minutes. The oral pouchproduct contains only tobacco-free flavor beads.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a pouched, oral tobacco product containingonly tobacco-free flavor beads.

FIG. 2 is an illustration of a cross-sectional view of a flavor beadincluding at least one coating.

DETAILED DESCRIPTION

Provided is an oral pouch product containing only tobacco-free flavorbeads. The tobacco-free flavor beads comprise microcrystalline cellulose(MCC), pectin and/or sodium alginate and at least one flavorant. Whenpectin and/or sodium alginate are used, the pectin and/or sodiumalginate are cross-linked. In addition, the flavor beads contain atleast one additional polymer that has a higher solubility in saliva thanMCC, cross-linked pectin and/or cross-linked sodium alginate. The flavorbeads provide immediate and long lasting flavor release during use.

As used herein, the term “an oral pouch product” generally denotes apouch product which fits in a user's mouth and delivers a desirabletaste, aroma, chemesthetic effect or combination of two or more of thesewhen placed through contact with the consumer's taste buds, olfactoryreceptors, or both, preferably via the consumer's saliva. The oral pouchproduct contains tobacco-free flavor beads that provide immediate andlong lasting release of flavors during use.

As used herein, the term “flavorant” denotes a compound having adesirable taste, aroma or both. Examples of suitable flavorants aredescribed herein.

In a first embodiment, the flavor beads can be prepared using knownextrusion and spheronization processes for producing pharmaceuticalpellets and flavored beads such as the techniques described in commonlyowned U.S. Patent Application Publication No. 2007/0000505, filed onFeb.22, 2006, the entire content of which is incorporated herein byreference.

Preferably, the extruded and spheronized tobacco-free flavor beads areformed by mixing microcrystalline cellulose (MCC) and at least oneadditional polymer having a higher solubility in saliva than MCC withwater to form a paste or dough, to which is added a solution,suspension, or emulsion of flavorant. In the preferred embodiment, theadditional polymer is hydroxypropyl methyl cellulose. The MCC,hydroxypropyl methyl cellulose, flavorant-containing liquid, and anyadditional water or aqueous solution added to obtain the desiredconsistency can be mixed using a ribbon blender, Banbury, or othermixing apparatus capable of mixing high solids content materials. Whilenot wishing to be bound by any theory, it is believed that the kneadingof the liquid flavorant with the solids causes the liquid to disperseinto the solid and become physically entrapped therein.

The dough-like material is then forced through an extruder to formstrands of extrudate. The extrudate is broken into short strands andspheronized to form wet spheres. The flavor beads can be spheronizedfrom the extrudate by using an LCI QJ-230T Marumerizer at a suitablerotation speed (e.g., 1200 RPM) for a suitable time (e.g., 10 minutes).Preferably, the flavor beads are then dried to remove a portion of theliquid. Additionally flavorants and/or coatings can be added to theflavor beads after drying.

In the preferred embodiment, the flavor beads contain MCC. MCC improvesthe physical strength, integrity, and processability of the flavor beads(e.g., during preparation of flavor beads). MCC is a structure-buildingmaterial which helps to provide physical encapsulation of the flavorantimmobilized in the flavor beads. In addition, due to the low solubilityof the MCC, it can also help to adjust the degradation and release rateof the flavorant during consumption of the oral pouch product. In thepreferred embodiment, MCC is added in an amount of at least about 50 wt%, based on the total weight of the flavor beads and more particularlyin an amount of about 60 wt % to about 80 wt % based on the total weightof the flavor beads.

Also preferably, the flavorant is added to the MCC containing flavorbeads in an amount of less than about 60 wt % based on the total weightof the flavor beads and more particularly in an amount of about 10 wt %to about 30 wt % based on the total weight of the flavor beads. Suitableflavorants include, without limitation, any natural or synthetic flavoror aroma, such as tobacco, menthol, peppermint, spearmint, chocolate,licorice, citrus, gamma octalactone, vanillin, ethyl vanillin, breathfreshener flavors, cinnamon, methyl salicylate, linalool, bergamot oil,geranium oil, lemon oil, ginger oil, pomegranate, acai, raspberry,blueberry, strawberry, gooseberry, wolfberry, mulberry, blackcurrant,redcurrant, sea buckthorn, blackberry, boysenberry, cranberry, bourbon,scotch, whiskey, cognac, hydrangea, lavender, apple, peach, pear,cherry, plum, orange, lime, grape, grapefruit, butter, rum, coconut,almond, pecan, walnut, peanut, hazelnut, French vanilla, macadamia,sugar cane, maple, cassis, caramel, banana, malt, espresso, kahlua,white chocolate, clove, cilantro, basil, oregano, curry, garlic,mustard, nutmeg, rosemary, thyme, tarragon, dill, sage, anise, fennel,jasmine, coffee, olive oil, sesame oil, sunflower oil, balsamic vinegar,rice wine vinegar, or red wine vinegar. Other suitable components mayinclude flavor compounds selected from the group consisting of an acid,an alcohol, an ester, an aldehyde, a ketone, a pyrazine, combinations orblends thereof and the like. Suitable flavor compounds may be selected,for example, from the group consisting of phenylacetic acid, solanone,megastigmatrienone, 2-heptanone, benzylalcohol, cis-3-hexenyl acetate,valeric acid, valeric aldehyde, ester, terpene, sesquiterpene,nootkatone, maltol, damascenone, pyrazine, lactone, anethole,iso-valeric acid, combinations thereof and the like.

Also preferably, the flavor beads contain at least one additionalpolymer having a higher solubility in saliva than MCC. In the preferredembodiment, the additional polymer is hydroxypropyl methyl cellulose.Preferably, the hydroxypropyl methyl cellulose is included in an amountof up to about 20 wt % based on the total weight of the flavor beads.Most preferably, the hydroxypropyl methyl cellulose is included in anamount of about 2 wt % to about 6 wt % based on the total weight of theflavor beads.

Not wishing to be bound by theory, it is believed that the hydroxypropylmethyl cellulose helps control the flavor release rate in the finaltobacco-free flavor beads because the hydroxypropyl methyl cellulose hasa higher solubility in saliva than MCC. As such, the hydroxypropylmethyl cellulose dissolves more quickly thereby releasing the flavorantmore quickly. Thus, the flavor bead's flavor release rate can beadjusted by changing the polymer ratio in the flavor bead. For example,flavor beads containing more hydroxypropyl methyl cellulose will have afaster flavor release rate than flavor beads having a lowerhydroxypropyl methyl cellulose content. Also, the hydroxypropyl methylcellulose provides a smooth and creamy texture to the flavor beads. Inaddition, the hydroxypropyl methyl cellulose exhibits lipophilliccharacteristics with excellent emulsification properties that aid inincorporating hydrophobic flavorants into the flavor beads.

Thus, preferred tobacco-free flavor beads comprising MCC releaseflavorants for about 15 to about 35 minutes (e.g. about 20 minutes toabout 35 minutes or about 25 minutes to about 30 minutes).

The following examples are exemplary and are not meant to limit anyaspects of the embodiments disclosed herein.

EXAMPLE 1

About 100 grams MCC, 10 grams of hydroxypropyl methyl cellulose and 80grams of berry flavor are well mixed with 100 grams of deionized waterto form a flavored wet mass at room temperature. The flavored wet massis extruded at 40 rpm using an LCI bench-scale extruder. The extrudateis spheronized at 1450 rpm by a LCI spheronizer at room temperature for5 minutes to form flavor beads. The flavor beads are then dried at about160° F. for about 2 hours by a food dehydrator to form MCC flavor beadshaving a diameter of about 1.0 mm and a moisture content of less thanabout 5%.

In a second embodiment, tobacco-free flavor beads can be formed viaionic gelation. Tobacco-free flavor beads formed by ionic gelationinclude pectin, sodium alginate or both. In the preferred embodiment,the pectin and sodium alginate are cross-linked. Also preferably, theflavor beads include at least one additional polymer that is moresoluble in saliva than the cross-linked pectin and/or the cross-linkedsodium alginate.

In a preferred embodiment, the pectin and/or sodium alginate areincluded in the flavor beads in an amount of at least about 0.5 wt %based on the weight of the flavor beads. The flavor beads can comprisepectin in an amount of up to about 90 wt %.

Preferably, the pectin and/or sodium alginate is cross-linked using asuitable cross-linking agent. Suitable cross-linking agents includemonovalent metal ion salt or a bivalent metal ion salt. While bothmonovalent and bivalent metal ion salts may be used, preferably abivalent metal ion salt is used. Suitable bivalent metal ion saltsinclude, without limitation, calcium lactate, calcium chloride, calciumsorbate, calcium propionate and the like. Calcium lactate is preferredsince it is approved for use in food products. Preferably, thecross-linking agent is included in the flavor beads in an amount of upto about 0.5 wt % based on the weight of the flavor beads.

Also preferably, the flavor beads comprise at least one modified starch.Preferred modified starches are those that have been modified withoctenyl succinic anhydride (generally referred to as NOSA starches orOSAn Starches). Preferred embodiments include a first modified starchand a second modified starch. Preferably, the first modified starch isHI-CAP 100, which is available from National Starch & Chemical Co.HI-CAP 100 is suitable for the encapsulation of flavorants and is alsocharacterized by excellent resistance to oxidation. Preferably, thesecond modified starch is N-CREAMER 46, also available from NationalStarch & Chemical Co., which is characterized by excellent emulsionstabilization. Preferably, the first starch is included in an amount ofup to about 20 wt % based on the weight of the flavor beads and thesecond starch is included in an amount of up to about 10 wt % based onthe weight of the flavor beads.

Not wishing to be bound by theory, it is believed that the addition of afirst starch and/or a second starch aids in controlling the flavorrelease rate of the flavor beads. Since the pectin and/or sodiumalginate are cross-linked during ionic gelation, the starches have ahigher solubility and thus release flavorants at a different rate thanpectin and/or sodium alginate. Thus, preferred flavor beads formed viaionic gelation release flavor for up to about 80 minutes in water and/orsaliva depending upon the polymer ratio contained therein. Preferably,the flavor beads contain multiple polymers having different solubilityso that the flavorants are released at different times so as to prolongthe experience of the user.

In addition, flavor beads containing starches taste smoother and/orcreamier than flavor beads formed without starches. Also, the modifiedstarches are polymers which exhibit lipophilic characteristics withexcellent emulsification properties. As such, the starches aid inencapsulating hydrophobic flavorants in particular.

Also preferably, the flavor beads formed by ionic gelation include atleast one flavorant. Suitable flavorants include those used in the MCCcontaining flavor beads described above. Preferably, the flavor beadsformed by ionic gelation include at least one flavorant in an amount ofup to about 60 wt % based on the weight of the flavor beads.

In the preferred embodiment, the flavor beads comprise about 50 wt % toabout 80 wt % pectin, about 5 wt % to about 10 wt % of the first starch,about 1 wt % to about 5 wt % of the second starch and about 15 wt % toabout 30 wt % flavorant.

EXAMPLE 2

About 2 ml of berry flavorant (e.g. strawberry, blueberry and/orraspberry flavorants), about 13 grams of pectin, about 1 gram of thefirst modified starch and about 0.5 gram of the second modified starchare homogenized with about 90 grams of distilled water at 4,500 rpm for10 minutes at room temperature. About 20 ml 5% calcium lactate solutionis added to the mixture and homogenized for about 2 minutes. The formedaqueous slurry is dried at about 160° F. for about 4 hours in a fooddehydrator. Then, the dried material is ground into small beads having adiameter of about 1.0 mm by a coffee blender to form flavor beads havinga moisture content of less than about 5%.

The resulting flavor beads containing at least one of MCC, pectin andsodium alginate are preferably in the form of spheroids that aresubstantially round or oval in shape. Also preferably, the flavor beadsrange in diameter from about 0.5 mm to about 2.0 mm (e.g., about 0.75 mmto about 1.75 mm or about 1.0 mm to about 1.5 mm).

In an embodiment, the flavor beads can further comprise at least onecoating on the external surface thereof. The coating is preferablyformed of a highly soluble material and at least one flavorant, suchthat flavorants are quickly released from the coating when placed in auser's mouth. Preferred coatings comprise corn zein, ethyl celluloseand/or food grade waxes. The flavorants in the coatings can be the sameflavorant or a different flavorant than the flavorant incorporated inthe flavor beads.

Once processed, the flavor beads 14 can be placed in a pouch wrapper 55to form an oral pouch product 50, as shown in FIG. 1. Preferably, noingredients other than the flavor beads 14 are contained in the oralpouch product 50.

The oral pouch products 50 that incorporate the flavor beads 14described herein can take various shapes, which are preferably designedto be inserted into the oral cavity, where they come into contact withthe user's saliva, and release flavorant into the saliva. Typically therelease of flavorant is designed to occur according to a time profile.For example, a flavorant release profile may include a burst offlavorant when the oral pouch product 50 is first introduced into theoral cavity, followed by a slow decrease in flavorant release over time,or may include a steady release of flavorant over the consumption of theoral pouch product 50. For example, the tobacco-free flavor beads 14contained within the pouch wrapper 55 can include a highly solublecoating 120 (shown in FIG. 2) that comprises flavorants 16. When placedin the mouth, the coating 120 quickly dissolves to release theflavorants 16.

In the preferred embodiment, the oral pouch products 50 described hereincontain only tobacco-free flavor beads 14. Thus, the flavor beads 14make up the majority of the weight of the finished oral pouch product50. In an embodiment, the flavor beads 14 substantially completely fillthe interior of the porous pouch wrapper 55. Alternatively, the flavorbeads 15 partially fill the interior of the porous pouch wrapper 55. Theoral pouch product 50 provides for the delivery of an engaging,flavorful, and/or aromatic experience by delivering flavorants to a userin a consumable unit designed to be inserted in the mouth. The flavorbeads 14 prepared as described herein and that contain the sameflavorant, or that contain two or more different flavorants, may be usedin an oral delivery pouch product 50 by introducing the flavor beads 14as filling material into the cavity of the pouch wrapper 55.

Preferably, the flavor beads 14 facilitate high-speed pouch fillingoperations during the manufacture of oral pouched products 50 becauseflavor beads 14 tend to more consistently and cleanly flow into and outof metering feed machinery, with less scatter and dusting than loose,irregular particles and/or fibers that can be contained in other oralpouch products.

As illustrated in FIG. 1, an oral pouch product 50 includes an innermaterial. The inner material comprises only flavor beads 14 enclosed ina pouch wrapper 55.

The porous pouch wrapper 55 described herein can be made of a porousmaterial, such as a paper or fabric, such as a nonwoven fabric or apaper of the type used to construct filters or tea bags. The porouspouch wrapper should be capable of allowing the flavors contained in theflavor beads of the oral pouch product to diffuse through the pouchwrapper and into the user's mouth. The porous pouch wrapper should alsobe capable of accepting the coating material as described herein.Desirably, the porous pouch wrapper is made from a material suitable forcontact with food, such as materials used in packaging or handlingfoods. Preferred porous materials include, but are not limited to,films, gelatin, food casings, carrageenan, biopolymers, fabric (woven ornon-woven), and/or paper such as filter paper, papers used to constructtea bags, coffee filters, and the like.

In a preferred embodiment, the porous membrane maintains sufficientstructural integrity during the time period that the pouch wrapper 55 isused so that the inner material is retained therein. In anotherembodiment, the pouch wrapper 55 may be dissolvable or disintegrable andcomposed of soluble polymers. In an embodiment, flavorants may be addedto the pouch wrapper 55 to provide additional flavor to the user.

Preferably, the oral pouch product 50 fits completely and comfortablyinside the user's mouth. Preferably, the oral pouch product 50 fitsdiscreetly within the user's mouth, and more preferably between thecheek and teeth or gums. A user can suck, chew, or otherwise orallymanipulate the pouch product 50 to release the flavors containedtherein.

The oral pouch product 50 may have a square, rectangle, circular, moon,crescent, or oblong shape. The oral pouch product 50 can also be shapedlike a half-moon or D-shape, or can take other shapes, including,without limitation oval, pouch-shape, rod-shape, cylindrical, tea leaf,tear drop, or hourglass shapes. In some embodiments, the pouch-shape canbe similar to a ravioli or pillow shape. Other shapes may be utilized solong as the shapes fit comfortably and discreetly in a user's mouth. Insome embodiments, the shape of the pouch can indicate the releasableingredient, such as the flavor. Thus, in these embodiments, the oralpouch product 50 may be shaped as fruits, vegetables, or other objectsthat connote a particular releasable ingredient. For instance, the oralpouch product 50 could be in the shape of a banana to indicate a bananaflavor or in the shape of a strawberry to indicate a strawberry flavor.

Preferably, sharp corners are avoided as sharp corners may lead to oraldiscomfort. The pouch wrapper 55 is sealed around one or more edges tocontain the flavor beads 14 within the pouch wrapper 55.

Preferably, the pores in the pouch wrapper 55 allow flavors to diffusethrough the material and into the user's mouth.

The oral pouch product 50 generally is sized and configured to fitcomfortably in a user's mouth. Preferably, the oral pouch product 50weighs about 0.2 g to about 5.0 g (e.g., about 0.1 g to about 1.0 g,about 1.0 g to about 2.0 g, about 2.0 g to about 3.0 g, about 3.0 g toabout 4.0 g or about 4.0 g to about 5.0 g). Also preferably, the oralpouch product 50 is about 0.25 inch to about 2.0 inches in width, about0.25 inch to about 2.0 inches in length, and about 0.25 inch to about2.0 inches thick. In an embodiment, the oral pouch product 50 is about0.1 inch to about 2.0 inches in width, about 0.1 inch to about 2.0inches in length and about 0.1 inch to about 2.0 inches thick.

The oral pouch product 50 can preferably deliver a plurality offlavorants to the user for a period of about 15 minutes to about 80minutes (e.g., about 20 minutes to about 75 minutes, about 25 minutes toabout 70 minutes, about 30 minutes to about 65 minutes, about 35 minutesto about 60 minutes, about 40 minutes to about 55 minutes or about 45minutes to about 50 minutes). Preferably, the oral pouch product 50 isdiscarded after a single use. Also preferably, the oral pouch product 50weighs between about 0.2 g and 5.0 g. The weight is predominately theresult of the weight of the enclosed tobacco-free flavor beads 14.

In an embodiment, the pouch wrapper 55 can also be provided with atleast one coating that can release flavorants or other ingredients tothe user's mouth when in contact with saliva.

In this specification, the word “about” is often used in connection withnumerical values to indicate that mathematical precision of such valuesis not intended. Accordingly, it is intended that where “about” is usedwith a numerical value, a tolerance of 10% is contemplated for thatnumerical value.

While the foregoing describes in detail tobacco products and methods offorming tobacco products with reference to a specific embodimentthereof, it will be apparent to one skilled in the art that variouschanges and modifications and equivalents to the method of treatingtobacco and forming tobacco products may be employed, which do notmaterially depart from the spirit and scope of the invention.

1. A tobacco-free oral pouch product providing immediate and longlasting flavor release comprising: a pouch wrapper; and tobacco-freeflavor beads contained within the pouch wrapper, the flavor beadscomprising: at least one of microcrystalline cellulose, pectin andsodium alginate, said pectin and said sodium alginate beingcross-linked; at least one polymer having a higher solubility in salivathan microcrystalline cellulose, pectin and/or sodium alginate; and atleast one flavorant, wherein the tobacco-free flavor beads provideimmediate release of the flavorant upon placement in a user's mouth andlong lasting release of the flavorant for about 15 minutes to about 80minutes and wherein the oral pouch product contains only tobacco-freeflavor beads.
 2. The oral pouch product of claim 1, wherein thetobacco-free flavor beads comprise about 60 wt % to about 80 wt %microcrystalline cellulose, about 2 wt % to about 6 wt % hydroxypropylmethyl cellulose and about 10 wt % to about 30 wt % flavorant.
 3. Theoral pouch product of claim 1, wherein the tobacco-free flavor beadscomprise at least about 50 wt % microcrystalline cellulose.
 4. The oralpouch product of claim 1, wherein the tobacco-free flavor beads compriseabout 0.5 wt % to about 80 wt % pectin, about 5 wt % to about 10 wt % ofa first modified food starch, about 15 wt % to about 30 wt % flavorant,about 0.001 wt % to about 0.5 wt % calcium lactate and about 1 wt % toabout 5 wt % of a second modified starch.
 5. The oral pouch product ofclaim 1, wherein the tobacco-free flavor beads further comprise at leastone coating.
 6. The oral pouch product of claim 5, wherein the at leastone coating is a food grade wax coating, a corn zein coating and/or anethyl cellulose coating.
 7. The oral pouch product of claim 1, whereinthe tobacco-free flavor beads have a diameter of about 0.5 mm to about2.0 mm.
 8. The oral pouch product of claim 1, wherein the tobacco-freeflavor beads have a density of about 0.8 to about 1.0 g/cm³.
 9. The oralpouch product of claim 1, wherein the moisture content of thetobacco-free flavor beads is less than about 5 wt %.